Method and apparatus for programming modular surgical instrument

Abstract

A surgical instrument operable to sever tissue includes a body assembly and a selectively coupleable end effector assembly. The end effector assembly may include a transmission assembly and an end effector. The body assembly includes a trigger and a casing having a distal aperture configured to receive a portion of the end effector assembly. First and second coupling mechanism portions cooperatively couple the end effector assembly to the body assembly for use. A cartridge positionable between the instrument and a generator includes information regarding operating parameters unique to the selectively coupleable end effector assembly and/or the desired surgical procedure, such as information regarding setting a maximum current set point within an ultrasonic transducer. The instrument is programmable with operating parameter information while within a sealed and sterilized packaging unit.

We claim: 
     
       1. A surgical instrument comprising:
 (a) an instrument body, the instrument body comprising an instrument power connector, wherein the body is operable to communicate with different kinds of end effector assemblies; 
 (b) a modular end effector assembly, wherein the modular end effector assembly is operable to removably couple with the body; 
 (c) a power source operable to drive the end effector, the power source comprising a power source connector; and 
 (d) a detachable control module associated with the modular end effector assembly, wherein the detachable control module is operable to control delivery of power from the power source to the end effector assembly, the program module comprising an input power connector and an output power connector;
 wherein the detachable control module comprises a cartridge and a program module programmed to store a set of operating parameters associated with the end effector assembly; 
 wherein the instrument power connector is adapted to be coupled with the output power connector; and 
 wherein the power source connector is adapted to be coupled with the input power connector. 
 
 
     
     
       2. The surgical instrument of  claim 1 , wherein the power source comprises a generator, wherein the detachable control module is disposable between the instrument body and the generator. 
     
     
       3. The surgical instrument of  claim 2 , wherein the detachable control module is configured to receive power from the generator, wherein the detachable control module is configured to transmit one or more stored operating parameters to a memory device of the surgical instrument upon receipt of power from the generator. 
     
     
       4. The surgical instrument of  claim 3 , wherein the detachable control module is removable from the position between the surgical instrument and the generator, and wherein the detachable control module is operable to remove the one or more stored operating parameters from the memory device of the surgical instrument upon decoupling of the detachable control module from the generator. 
     
     
       5. The surgical instrument of  claim 1 , wherein the program module comprises an EEPROM chip. 
     
     
       6. The surgical instrument of  claim 1 , wherein the power source comprises a generator, wherein the program module is integral with the cartridge, wherein the cartridge is configured to couple with a docking station disposed between the surgical instrument and the generator, wherein the docking station is connected to each of the surgical instrument and the generator via a respective electrical conduit. 
     
     
       7. The surgical instrument of  claim 1 , further comprising one or more electrical conduits, wherein the program module is removable from the cartridge and is operable to attach at least one electrical conduit connected to the surgical instrument. 
     
     
       8. The surgical instrument of  claim 1 , further comprising one or more electrical conduits, wherein the program module is removable from the cartridge and is operable to couple at least one of the electrical conduits with the power source. 
     
     
       9. The surgical instrument of  claim 8 , wherein the program module is configured to attach the at least one electrical conduit to the power source via magnetic forces. 
     
     
       10. The surgical instrument of  claim 1 , wherein the end effector assembly comprises an ultrasonic end effector assembly including an ultrasonic blade. 
     
     
       11. The surgical instrument of  claim 1 , wherein the end effector assembly comprises an RF electrosurgical end effector assembly. 
     
     
       12. The surgical instrument of  claim 1 , wherein the modular end effector assembly is operable to detachably couple to the body via a threaded connection. 
     
     
       13. The surgical instrument of  claim 1 , further comprising a docking station assembly, wherein the detachable control module is attachable to the docking station assembly. 
     
     
       14. The surgical instrument of  claim 13 , wherein the docking station assembly is in communication with a computer via a wireless connection, and wherein the detachable control module is configured to at least one of transmit or receive a wireless signal including data to or from the computer when the detachable control module is coupled with the docking station assembly. 
     
     
       15. The surgical instrument of  claim 1 , wherein the input power connector is a first end of the program module, and the output power connector is a second end of the program module. 
     
     
       16. The surgical instrument of  claim 1 , wherein the set of operating parameters comprises a current set point and a procedure type, and wherein a cutting speed of the surgical instrument is determined based at least in part upon the current set point and the procedure type. 
     
     
       17. The surgical instrument of  claim 1 , wherein the instrument power connector comprises a first length of external cable, and wherein the power source connector comprises a second length of external cable. 
     
     
       18. A surgical instrument comprising:
 (a) a handle assembly, wherein the handle assembly is operable to communicate with different kinds of end effector assemblies, wherein the handle assembly comprises a pistol grip and a trigger pivotable toward and away from the pistol grip, the handle assembly comprising an instrument power connector; 
 (b) a first modular end effector assembly, wherein the modular end effector assembly is operable to removably couple with the handle assembly; 
 (c) a power source operable to drive the end effector, the power source comprising a power source connector; 
 (d) a first detachable control module associated with the first modular end effector assembly, wherein the first detachable control module stores a first set of operating parameters configured to operate the first modular end effector assembly, the first detachable control module comprising a first input power connector and a first output power connector; 
 (e) a second module end effector assembly, wherein the second modular end effector assembly is operable to removably couple with the handle assembly; and 
 (f) a second detachable control module associated with the second modular end effector assembly, wherein the second detachable control module stores a second set of operating parameters configured to operate the second modular end effector assembly, the second detachable control module comprising a second input power connector and a second output power connector;
 wherein the instrument power connector is adapted to be coupled with the first output power connector and the second output power connector; 
 wherein the power source connector is adapted to be coupled with the first input power connector and the second input power connector; 
 wherein a user determines a set of operating parameters for a modular end effector assembly by attaching a detachable control module, the detachable control module selected from the list consisting of the first detachable control module and the second detachable control module. 
 
 
     
     
       19. A surgical instrument comprising:
 (a) an instrument body, wherein the body is operable to communicate with different kinds of end effector assemblies, the instrument body comprising an instrument power connector; 
 (b) a modular end effector assembly, wherein the modular end effector assembly is operable to removably couple with the body; 
 (c) a power source operable to drive the end effector, the power source comprising a power source connector; 
 (d) a detachable control module associated with the modular end effector assembly, the detachable control module comprising an input power connector and an output power connector, wherein the detachable control module stores a set of operating parameters; and 
 (e) a docking station assembly, wherein the detachable control module is attachable to the docking station assembly;
 wherein the instrument power connector is adapted to be coupled with the output power connector; 
 wherein the power source connector is adapted to be coupled with the input power connector; 
 wherein the modular end effector assembly is operable based upon the set of operating parameters; and 
 wherein the docking station assembly is operable to modify the set of operating parameters when the detachable control module is attached to the docking station assembly.